Laser cutting machine for the working of material, presented in sheet and/or reel form

Abstract

A laser cutting machine including an X1 axis provided with clamps which make it possible to firmly grip a material to be cut in sheets or on reels (the blank) enabling the material to be moved from left to right; a Y-axis: perpendicular to the X1 axis, enabling the movement of a laser cutting head; an X2 axis with at least one pair of clamping rollers enabling the material to be moved to the left or to the right; a straightening/de-cambering/levelling system placed beside this X2 axis comprising an optimised number of rollers; a unit incorporating the X2 axis and the straightening system which can be moved upwards or downwards, and a motorized discharge table enabling the cut elements (scrap and good pieces) to be discharged at a precise point, delimiting a picking zone.

Claims

1. A laser cutting machine comprising: clamps, arranged on a clamp rail disposed along an X1 axis, wherein the clamps are configured to grip uncut material, wherein the uncut material is configured in sheets or on reels, so that the laser cutting machine is configured to move the uncut material from left to right along the X1 axis, a laser cutting head arranged on a head rail disposed along a Y axis, perpendicular to the X1 axis, so that the laser cutting head is configured to move along a Y axis, clamping rollers configured to rotate about an X2 axis, a rotational centre of which extends along the Y axis, and the clamping rollers being configured to move the uncut material to the left or to the right along the X1 axis, a straightening system configured for straightening, de-cambering and levelling the uncut material, disposed adjacent the X2 axis relative to the X1 axis, and comprising a plurality of rollers defining a roller rotational axis that is along the Y axis, a unit disposed on a first side of the head rail along the X1 axis, the first side defining a material feed side of the laser cutting machine, the unit including the clamping rollers and the straightening system, wherein the unit is configured to move along an up-down axis, in a direction perpendicular to the X1 axis and Y axis, thereby moving the clamping rollers and straightening system along an up-down axis, and a motorised discharge table disposed on a second side of the head rail along the X1 axis, defining a material discharge side of the laser cutting machine, configured to discharge cut elements, including scrap and non-scrap, at a location along the X1 axis on the second side of the head rail, wherein in operation, the straightening system, the unit, the head rail, and the motorised discharge table are configured to move along the X1 axis, toward the material discharge side, while the laser cutting head is cutting the uncut material.

2. The laser cutting machine according to claim 1, wherein the unit defines an upper part, wherein the upper part defines an upper surface, wherein the upper part includes brushes configured to limit friction between the upper surface and the uncut material.

3. The laser cutting machine according to claim 2, wherein the unit is configured to be disposed in a parking position, defining a bottom position, at which the upper surface of the unit is level with, along the up-down axis, a pass line of the laser cutting machine.

4. The laser cutting machine according to claim 3, wherein the unit is configured to be disposed in a working position, defining a top position, at which the unit is positioned so that the X2 axis is level with, along the up-down axis, the pass line.

5. The laser cutting machine according to claim 1, including a recovery tray or a motorised conveyor, located below, along the up-down axis, the laser cutting head, configured to receive discharged materials from the laser cutting machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Other special features and characteristics of the disclosed embodiments will emerge from the appended drawings in which:

(2) FIG. 1 shows a layout for a preferred embodiment in blank cutting mode (the X2/straightening/de-cambering/levelling unit) being in the bottom position (=at rest=parking);

(3) FIG. 2 shows a diagrammatic view of a X, Y cutting gantry;

(4) FIG. 3 shows a layout for a preferred embodiment in cutting from a reel mode (the X2/straightening/de-cambering/levelling unit) being in the top position;

(5) FIG. 4 is a schematic overview of a machine which cuts only from reels;

(6) FIG. 5 shows a layout for a preferred embodiment in cutting from a reel mode as carried out on a line (FIG. 4);

(7) FIG. 6 is a diagrammatic view of the top showing the layout of the various elements of a machine for cutting from reels and from flat blanks;

(8) FIGS. 7 to 11 illustrate the cutting of a shaped piece from a blank; and

(9) FIGS. 12 to 15 illustrate the cutting of material scrap to be extracted from the middle of the blank.

DETAILED DESCRIPTION

(10) With continued reference to the various figures, special features and characteristics of the disclosed embodiments will emerge from the detailed description of an advantageous production mode of the machine 100.

(11) In effect, this machine 100 configuration combines the separate operating modes of the cutting gantry (A) and the cutting line from reels (B), that is to say that the machine 100 enables the material to be worked on from flat blanks but also from reels.

(12) The proposed machine 100 configuration makes it possible to discharge cut pieces and waste in a continuous flow, as the discharge of pieces is localised at a specific point using a motorised discharge table and/or a collecting tray and motorised conveyor.

(13) The discharge of pieces 110 (parts and scrap, FIGS. 7-11) may be easily automated using a handling robot 120. Alternatively, an operator 130 may recover the pieces 110 manually and carry out a shaping operation such as rolling for producing a ferrule, or moulding, etc. The flow of cut material is continuous, so it is not necessary to wait for the entire metal sheet to be cut (as it is for the cutting gantry).

(14) The machine 100 therefore operates in a continuous flow but it also takes up less space than configuration B and the reel-straightener distance is shortened; therefore only one control loop is necessary.

(15) In a preferred configuration, the machine 100 comprises:

(16) An X1 axis provided with clamps 140 (FIG. 1, shown schematically) which make it possible to hold the blank 150 (uncut material) firmly. The movement of the X1 axis to the left or to the right therefore causes a similar movement of the material 150 to be cut.

(17) A Y-axis: perpendicular to the X1 axis. The Y-axis takes up the movement of the laser cutting head 160 (Z-axis or up-down axis 165 (FIG. 1) and optional Xa along the X1 axis and Ya axis along the Y axis).

(18) An X2 axis provided with a pair of clamping rollers 170. The rotational direction (clockwise or anticlockwise) causes the sheet metal 150 to move to the left or to the right. A straightening/de-cambering/levelling system 180 is placed next to this X2 axis which includes a number (plurality) of rollers 190 proportional to the type and thickness of the material 150 to be straightened. Generally speaking, the thicker the material or more non-plastic the material, the greater the number of straightening rollers 190. The positioning of these rollers 190 can be done manually or in a motorised fashion.

(19) A unit 200 including X2 and the straightening system 180. This unit 200 moves upwards or downwards and in its upper part 210 (FIG. 3) is provided with a compatible material limiting friction on the material 150 to be cut (this may typically be brushes 230, shown schematically, but not exclusively). In the bottom position (=parking position or rest position), the upper surface 220 is aligned with the machine's pass line 240. In the top position, the unit 200 is positioned so that the X2 axis is at the same level as the pass line. It is in this top position that the unrolling of the sheet metal 150 via X2 may take place.

(20) A motorised discharge table 250. The travel direction is perpendicular to the X1 axis, but not necessarily. In effect, the travel direction may be parallel to the X1 axis. The objective of this motorised table 250, in combination with specific operating cycles, is to discharge cut elements 110 (scrap and good uses, including parts) at a precise point.

(21) The machine 100 can operate in two separate operating cycles.

(22) Sheet by sheet: the operator 130 lays down the blank 150 and positions it in the clamps 140. The combination of the movements of the X1 and Y axes combined with the cutting head 160 enables cutting to take place. Operation in conjunction with the motorised table 250/discharge conveyor tray 260 enables the discharge of cut pieces and scrap.

(23) To this end, cuts always take place with the movement of X1 from the right to the left, with each cut element falling naturally onto the table 250. Once the complete length of the sheet metal is cut, the latter makes an unladen movement from the left to the right. Once this movement has been carried out, the laser cutting head 160 positions itself and the cutting operation takes place by moving the X1 axis from the right to the left, etc. it is clear that the machine 100 may also be configured with a passing direction of the material from the left to the right,

(24) From reels: the unit 200 including X2 and the straightener (straightening system 180) is positioned in height so that the X2 axis is at the same height that the machine 100 passes X2 and then unroll the reel 270 over a length optimised according to the pieces to be produced.

(25) Once the desired length is reached, the clamps 140 are activated to hold the sheet metal 150, and the laser head 160 cuts the sheet metal 150. As soon this happens, the unused piece reverses via X2 to a position which allows the X2 and straightening/de-camping/levelling unit 200 to be lowered to the bottom position.

(26) In fact, the sheet metal 150 which is held in the clamps 140 on the X2 axis may undergo a cutting cycle according to the sheet-by-sheet mode described above, with the latter being on the pass line.

(27) The machine 100 makes it possible to have a true operating mode sheet-by-sheet and from reels, which is unique.

(28) The combination of the discharge table 250/tray and discharge conveyor 280 (shown schematically in FIG. 1) and cutting cycles makes it possible to have efficient discharge of cut pieces in a continuous flow, which is not the case with configurations A and B.

(29) Other special features and characteristics of the disclosed embodiments will emerge from the appended drawings in which:

(30) FIG. 1 shows a layout for a preferred embodiment in blank cutting mode (the X2/straightening/de-cambering/levelling unit) being in the bottom position (=at rest=parking). FIG. 1 shows a reel 270 of sheet material 150, a unit 200 with clamping rollers 170 and a straightening system 180, a clamp rail 290 with clamps 140 (or clamping grippers, shown schematically), a laser cutting head 160 on a head rail 300 (shown schematically), a discharge table 250, a discharge tray 260 and a pass line 240. The head rail 300 extends in a Y direction (FIG. 2) that is perpendicular to the X1 axis.

(31) The unit 200 is on one side 305 (the feed side) relative to the X1 direction of the head rail 300 and the discharge table 250 is on another side (the discharge side) 315 relative to the X1 direction of the head rail 300. Motion of the discharge table 250 is shown with arrows 250a along discharge direction +X1, 250b in a reverse-feed direction −X1, 250c upwardly along an up-down axis 165, 250d downwardly along the up-down axis. Rotational motion of the clamping rollers 170 is shown with axis X2, in clockwise +X2 and counterclockwise −X2 directions. Motion of the head rail 300 is shown along the X1 axis in a discharge direction +X1 and a reverse-feed direction −X1, e.g., toward the reel 270. As explained below, in operation, the discharge table 250, discharge tray 260, the head rail 300 and the unit 200 move in the discharge direction while the unit 200 receives uncut stock (material blank) from the reel 270.

(32) FIG. 2 shows a diagrammatic view of a X, Y cutting gantry 320. The cutting head 160 moves along +Y and −Y directions. The configuration enables complete scanning of the table 250 which the uncut material 150 is found.

(33) FIG. 3 shows a layout for a preferred embodiment in cutting from a reel mode the X2/straightening/de-cambering/levelling unit 200 being in the top position such that the X2 axis is level with the pass line 240. The unit 200, head rail 300 discharge table 250 and discharge tray 260 are at a right-most position, e.g., along the material reverse-feed direction −X1.

(34) FIG. 4 is a schematic overview of a machine 100 which cuts only from reels 270. The figure shows uncut material 150, two pair of clamping rollers 170a, 170b the cutting head 160 on the head rail.

(35) FIG. 5 shows a layout for a preferred embodiment in cutting from a reel mode as carried out on a line (FIG. 4). The two loops (1 and 2) are represented. This figure shows a reel 270, the straightening system 180, and a laser cutting head 160.

(36) FIG. 6 is a diagrammatic view of the top showing the layout of the various elements of a machine 100 for cutting from reels 270 and from flat blanks 150. It is important to stress that the two separate operating modes cohabit (from flat blanks) and from reels, the clamps 140 as indicated are coincident in both cases but do not interfere, in summary their mechanical constitution and position makes both operating modes possible.

(37) FIGS. 7 to 11 illustrate the cutting of a shaped piece from a blank, the blank is located to the right of the laser cutting head 160, the discharge of the piece can be done favourably by the motorised discharge table 250 which is to the left of the laser cutting head 160. Gradually the X1 axis will move to the left and the Y-axis will also move; the conjunction of these two axes will determine the path of the cut which will appear between FIGS. 8 to 10, and which finally in FIG. 11 will discharge the piece through the movement of the motorised discharge table 250, discharging the part and scrap 110 outside the machine 100 to the picking zone 330.

(38) The cycle can continue, the X1 axis moves the remaining sheet metal (represented by hatching and positioned to the right), and the next cut can start etc.

(39) FIGS. 12 to 15 illustrate the cutting of material scrap to be extracted from the middle of the blank 150. The blank 150 is located to the right of the cutting head 160, the discharge of the scrap which is cut into successive slices which will fall downwards into the recovery tray/motorised conveyor 280. Gradually the X1 axis will move to the left and the Y-axis will also move; the conjunction of these two axes will determine the path of the cut which will appear between FIGS. 12 to 15, to finally discharge a round shape 340 in this example (any geometric shape whatsoever can also be cut).

(40) To sum up, this laser cutting machine 100 makes it possible to cut from reels 270, the suitable clamping of the flat blank and the suitable discharge of cut pieces and scrap result in the most optimised solution which can exist on the market in order to:

(41) Save material,

(42) Produce an extremely flush “nesting” between parts because a rigid skeleton is no longer necessary,

(43) Remove the need to keep a skeleton once the pieces are cut,

(44) And therefore suitable elimination of scrap in small elements,

(45) Intelligent recovery in a continuous flow of cut elements=no dead time,

(46) Possible integration of an automatic system for the loading and unloading of material/the machine can therefore work autonomously over long periods/or a manual solution for loading/unloading operations.

(47) Control System and Software

(48) This patent application does not describe the automation and the system which allows the shape and dimensions of the pieces to be cut to be determined. The most generally used software system described as a dedicated CAD/CAM within the applicable sector (HVAC, thermal insulation, etc.) combined with a “nesting” type application to limit material scrap. These CAD/CAM and nesting systems are used in all modern cutting systems, whether these are cutting gantries, or systems that cut from a reel. These CAD/CAM and nesting systems can be easily adapted by a skilled person to correspond to the machine's functionality and geometry.

(49) Cutting Strategy

(50) A technique used for the cutting of thin sheet metal and low-resistance material (e.g. thin aluminum from 0.4 to 0.7 mm used in thermal insulation) consist of leaving micro-fasteners between the various pieces. When the cutting process on a metal sheet of determined dimensions is finished, the blank is extracted from the machine and the pieces are detached manually, the micro-fastener then being broken by a repetitive cracking movement or by a pair of scissors. The shaped pieces to be recovered and the scraps are then sorted manually. This working method may sometimes be preferred depending on the type of user. For example, blanks may be precut with micro-fasteners in a centralised workshop and then be sent flat to a decentralised site to be processed there.

(51) This laser cutting machine can clearly accept this working method which is fundamentally connected to the cutting pass which will be generated by the CAD/CAM system.

(52) As indicated above, a laser cutting machine 100 is provided. The machine 100 includes clamps 140, arranged on a clamp rail 290 disposed along an X1 axis. The clamps 140 are configured to grip uncut material 150. The uncut material 150 is configured in sheets or on reels 270. The laser cutting machine 100 is configured to move the uncut material 150 from left to right, i.e., along the X1 axis.

(53) A laser cutting head 160 is arranged on a head rail 300 disposed along a Y axis, which is perpendicular to the X1 axis. The laser cutting head 160 is configured to move along a Y axis.

(54) Clamping rollers 170 are configured to rotate about an X2 axis, a rotational centre 310 (FIG. 4) of which extends along the Y axis. The clamping rollers 170 are configured to move the uncut material 150 to the left or to the right, i.e., along the X1 axis.

(55) A straightening system 180 (otherwise referred to as the straightening/de-cambering/levelling system) is configured for straightening/de-cambering/levelling the uncut material 150. the straightening system 180 is disposed adjacent the X2 axis relative to the X1 axis. The straightening system 180 includes a plurality of rollers 190 defining a roller rotational axis 310 that is along the Y axis.

(56) A unit 200 disposed on one side 305 of the head rail 300 along the X1 axis. The one side 305 defining a material feed side of the laser cutting machine 100. The unit 200 includes the clamping rollers 170 and the straightening system 180. The unit 200 is configured to move along an up-down axis 165, i.e., in a direction perpendicular to the X1 axis and Y axis. This moves the clamping rollers 170 and straightening system 180 in the up-down axis 165.

(57) A motorised discharge table 250 is disposed on another side 315 of the head rail 300 along the X1 axis, defining a material discharge side of the laser cutting machine 100. The motorised discharge table 250 is configured to discharge cut elements 110, including scrap and non-scrap, at a location along the X1 axis on the other side 315 of the head rail 300.

(58) In operation, the unit 200, the head rail 300, and the motorised discharge table 250 are configured to move along the X1 axis, toward the material discharge side X, while the laser cutting head 160 is cutting the uncut material 150, e.g. feed from the reel.

(59) In one embodiment, the unit 200 defines an upper part 210. The upper part defines an upper surface 220. The upper part 210 includes brushes 230 configured to limit friction between the upper surface 220 and the uncut material 150.

(60) In one embodiment, the unit 200 is configured to be disposed in a parking position, defining a bottom position. In the bottom position, the upper surface 220 of the unit 200 is level with, in the up-down axis 165, a pass line 240 of the laser cutting machine 100.

(61) In one embodiment, the unit 200 is configured to be disposed in a working position, defining a top position. In the top position, the unit 200 is positioned so that the X2 axis level with, in the up-down axis 165, the pass line 240.

(62) In one embodiment, a recovery tray or a motorised conveyor 280, located below, along the up-down axis 165, the laser cutting head 160. The recovery tray 260 or a motorised conveyor 280 is configured to receive discharged materials from the laser cutting machine 100.

(63) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.

(64) Those of skill in the art will appreciate that various example embodiments are shown and described herein, each having certain features in the particular embodiments, but the present disclosure is not thus limited. Rather, the present disclosure can be modified to incorporate any number of variations, alterations, substitutions, combinations, sub-combinations, or equivalent arrangements not heretofore described, but which are commensurate with the scope of the present disclosure. Additionally, while various embodiments of the present disclosure have been described, it is to be understood that aspects of the present disclosure may include only some of the described embodiments. Accordingly, the present disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.